US11577492B2 - Protective display film with glass - Google Patents

Protective display film with glass Download PDF

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Publication number
US11577492B2
US11577492B2 US16/335,537 US201716335537A US11577492B2 US 11577492 B2 US11577492 B2 US 11577492B2 US 201716335537 A US201716335537 A US 201716335537A US 11577492 B2 US11577492 B2 US 11577492B2
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layer
transparent
energy dissipation
display film
less
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US20200016868A1 (en
Inventor
V Joseph W. Woody
David Scott Thompson
Catherine A. Leatherdale
Ryan M. Braun
Michael A. Johnson
Steven D. Solomonson
John J. Stradinger
Lyudmila A. Pekurovsky
Joseph D. Rule
Peter D. Condo
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3M Innovative Properties Co
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3M Innovative Properties Co
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Assigned to 3M INNOVATIVE PROPERTIES COMPANY reassignment 3M INNOVATIVE PROPERTIES COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: THOMPSON, DAVID SCOTT, RULE, JOSEPH D., WOODY, JOSEPH W., V, JOHNSON, MICHAEL A., SOLOMONSON, STEVEN D., BRAUN, Ryan M., LEATHERDALE, CATHERINE A., PEKUROVSKY, LYUDMILA A., STRADINGER, JOHN J., CONDO, PETER D.
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/308—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising acrylic (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B32B27/325—Layered products comprising a layer of synthetic resin comprising polyolefins comprising polycycloolefins
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    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F1/00—Details not covered by groups G06F3/00 - G06F13/00 and G06F21/00
    • G06F1/16—Constructional details or arrangements
    • G06F1/1613—Constructional details or arrangements for portable computers
    • G—PHYSICS
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    • G06F1/1633—Constructional details or arrangements of portable computers not specific to the type of enclosures covered by groups G06F1/1615 - G06F1/1626
    • G06F1/1637—Details related to the display arrangement, including those related to the mounting of the display in the housing
    • G06F1/1652—Details related to the display arrangement, including those related to the mounting of the display in the housing the display being flexible, e.g. mimicking a sheet of paper, or rollable
    • H01L27/3244—
    • H01L51/0097—
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K50/00—Organic light-emitting devices
    • H10K50/80—Constructional details
    • H10K50/84—Passivation; Containers; Encapsulations
    • H10K50/844—Encapsulations
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K59/00—Integrated devices, or assemblies of multiple devices, comprising at least one organic light-emitting element covered by group H10K50/00
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K59/00—Integrated devices, or assemblies of multiple devices, comprising at least one organic light-emitting element covered by group H10K50/00
    • H10K59/10—OLED displays
    • H10K59/12—Active-matrix OLED [AMOLED] displays
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K59/00—Integrated devices, or assemblies of multiple devices, comprising at least one organic light-emitting element covered by group H10K50/00
    • H10K59/80—Constructional details
    • H10K59/87—Passivation; Containers; Encapsulations
    • H10K59/873—Encapsulations
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K77/00—Constructional details of devices covered by this subclass and not covered by groups H10K10/80, H10K30/80, H10K50/80 or H10K59/80
    • H10K77/10—Substrates, e.g. flexible substrates
    • H10K77/111—Flexible substrates
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/04—4 layers
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/26—Polymeric coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
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    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
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    • B32B2315/00—Other materials containing non-metallic inorganic compounds not provided for in groups B32B2311/00 - B32B2313/04
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    • H01L2251/5338—
    • H—ELECTRICITY
    • H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K2102/00—Constructional details relating to the organic devices covered by this subclass
    • H10K2102/301—Details of OLEDs
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
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    • Y02E10/50—Photovoltaic [PV] energy
    • Y02E10/549—Organic PV cells

Definitions

  • FIG. 5 is a schematic diagram side elevation view of an illustrative display film on an optical display forming an article
  • FIG. 7 is a stress-strain graph illustrating the elastic and plastic regions, proportional and elastic limits, and the breaking point for a material.
  • display film “protective film”, “cover sheet film”, and “protective display film” are herein used interchangeably.
  • the term may include “polyurethane-ureas” in which both urethane linkages and urea linkages are present.
  • Polyurethane acrylate refers to a polymer that includes primarily urethane and acrylate moieties or segments.
  • glass transition temperature refers herein to the “on-set” glass transition temperature by DSC and is measured according to ASTM E1256-08 2014.
  • protection layer may also be referred to as an abrasion resistant layer.
  • the present disclosure relates to display film with glass that protects a display or display window and may survive flexing, folding or impact tests.
  • the protective display film maintains optical properties of a display film while providing durability to the display.
  • the protective display film generally includes an energy dissipation layer fixed to a thin glass layer. This protective display film enables displays to survive impact events and recover from bending.
  • the protective display film includes an energy dissipation layer fixed to a thin glass layer.
  • the thin glass layer may be less than 500 micrometers, or less than 300 micrometers, or less than 200 micrometers, or less than 100 micrometers or less than 50 micrometers.
  • the energy dissipation layer may be a cross-linked polymer such as a cross-linked polyurethane material or a cross-linked polyurethane acrylate material.
  • the energy dissipation layer has a Tan Delta peak value of 0.5 or greater, or 0.8 or greater, or 1.0 or greater, or 1.2 or greater.
  • the energy dissipation layer or layers have a Young's Modulus (E′) greater than 0.9 MPa over the temperature range of ⁇ 40 degrees Celsius to 70 degrees Celsius.
  • the protective display film can include a layered structure including a protective layer.
  • Optional border elements may be created by die-cut (or otherwise converted) decorative film inserted between any layer(s) in the display film construction. While the present disclosure is not so limited, an appreciation of various aspects of the disclosure will be gained through a discussion of the examples provided below.
  • the transparent energy dissipation layer may not be a pressure sensitive adhesive or function as a pressure sensitive adhesive.
  • the transparent energy dissipation layer has a Young's Modulus larger than 0.9 MPa over the temperature range ⁇ 40 degrees Celsius to 70 degrees Celsius.
  • FIG. 2 is a schematic diagram side elevation view of an illustrative display film 20 that includes a protective layer 15 .
  • the protective layer 15 is disposed on the transparent glass layer 12 , and the transparent glass layer 12 separates the transparent energy dissipation layer 14 from the protective layer 15 .
  • the protective layer 15 may be directly fixed or coupled to the glass layer 12 .
  • the protective layer 15 may be directly fixed to the transparent glass layer 12 .
  • the protective layer 15 may be coated directly onto the transparent glass layer 12 .
  • the protective layer 15 may encompass one or more of edges of the transparent glass layer 12 .
  • the protective layer 15 may be directly fixed to a transparent substrate and the transparent substrate may be directly fixed to the transparent glass layer 12 .
  • FIG. 4 is a schematic diagram side elevation view of an illustrative display film 40 that includes an optically clear adhesive layer 13 fixing the protective layer 15 to the glass layer 12 .
  • the protective layer 15 may encompass one or more of edges of the transparent glass layer 12 .
  • the protective layer 15 may be directly fixed to a transparent substrate and the transparent substrate may be directly fixed to the transparent glass layer 12 .
  • the protective layer 15 may be coated directly onto the optically clear adhesive layer 13 .
  • the display film may include one or more additional layers. Additional layers may include conductive layers for touch sensitive display elements or barrier layers.
  • One or more additional transparent polymeric substrate layers may be disposed in the display film of any useful polymeric material that provides desired mechanical properties (such as dimensional stability) and optical properties (such as light transmission and clarity) to the display film. Examples of materials suitable for use in the polymeric substrate layer include polymethylmethacrylate, polycarbonate, polyamides, polyimide, polyesters (PET, PEN), polycyclic olefin polymers, and thermoplastic polyurethanes.
  • the optional one or more barrier layers may include a transparent barrier layer.
  • the transparent barrier layer may be disposed on the glass layer or the protective layer or the energy dissipation layer.
  • the transparent barrier layer can mitigate or slow ingress of oxygen or water through the display film.
  • Transparent barrier layers may include for example, thin alternating layers of silica, alumina or zirconia together with an organic resin. Exemplary transparent barrier layer are described in U.S. Pat. No. 7,980,910 and WO2003/094256.
  • the overall thickness of the display film described herein may have any useful value depending on the application.
  • the thickness of the display film is a balance between being thick enough to provide the desired display protection and thin enough to provide the level of flexibility desired for the device application and reduced thickness to meet desired design parameters.
  • the level of flexibility desired is a display film having a bend radii of 5 mm or less, or 4 mm or less, or 3 mm or less or in a range from 1 to 5 mm.
  • the overall thickness of the display film may be in a range from 30 to 300 micrometers, or from 40 to 200 micrometers, or from 40 to 150 micrometers.
  • the display film moderately flexes it may have total thickness in a range from 300 to 500 micrometers.
  • the display film is curved but does not appreciably flex, it may have total thickness in a range from 500 to 1000 micrometer
  • the display films described herein may have a haze value of 2% or less, or 1.5% or less, or 1% or less, or 0.5% or less. In some embodiments the display film may have a haze value of 5% or less.
  • the display film may have a clarity of 98% or greater, or 99% or greater.
  • the display film may have a visible light transmission of 85% or greater, or 90% or greater, or 93% or greater.
  • the display film may have a yellow index or b* value of 5 or less, or 4 or less, or 3 or less, or 2 or less, or 1 or less. In many embodiments the display film may have a yellow index or b* value of 1 or less.
  • the transparent glass layer 12 may be formed of any useful glass material.
  • the transparent glass layer 12 may be treated to provide beneficial properties.
  • the transparent glass layer 12 may be ion implanted, chemically strengthened or tempered, and the like.
  • the transparent glass layer 12 may have a thickness that is appropriate for a given bend radius or radius of curvature.
  • the transparent glass layer 12 may have a thickness of 500 micrometers or less, or from 300 micrometers or less or from 10 to 200 micrometers, or from 25 to 100 micrometers or from 25 to 50 micrometers.
  • Suppliers of thin transparent glass include Corning, Nippon Electric Glass, Schott and Asahi Glass.
  • the energy dissipation layer may have a Tan Delta peak value of 0.5 or greater, or 0.8 or greater, or 1.0 or greater, or 1.2 or greater, or from 0.5 to 2.5, or from 1 to 2.5, or from 1 to 2.
  • the energy dissipation layer or layers have a Young's Modulus (E′) greater than 0.9 MPa over the temperature range ⁇ 40 degrees Celsius to 70 degrees Celsius.
  • E′ Young's Modulus
  • the energy dissipation layer may be formed of a plurality of layers, and at least two of these layers having a different glass transition temperature value. These layers may have a different glass transition temperature value by at least 2 degrees Celsius, or at least 5 degrees Celsius, or at least 10 degrees Celsius, for example. In some cases, each energy dissipation layer peak Tan Delta values may occur at different frequencies at a specified temperature.
  • the energy dissipation layer may have a thickness of at least 20 micrometers or at least 30 micrometers or at least 50 micrometers.
  • the energy dissipation layer may have a thickness in a range from 20 to 200 micrometers, or 50 to 150 micrometers, or from 75 to 150 micrometers.
  • the thickness of the energy dissipation layer may be a balance between being thick enough to provide the desired protection to the display and thin enough to provide the dynamic performance requirements and/or reduced thickness for industrial design considerations.
  • a transparent cross-linked polyurethane layer preferably includes chemically or covalently crosslinked materials derived from step growth polymerization of isocyanate and polyol oligomers. Selection of reactant isocyanates and polyols may modify the glass transition temperature of the resulting cured polyurethane.
  • the cross-linked polyurethane layer may be coated onto the transparent polymeric or glass substrate layer (that may be primed) and then be cured or cross-linked to form a thermoset polyurethane layer.
  • the cross-linked polyurethane layer could be produced as a film that is then laminated to the transparent glass layer in a subsequent process step. Such lamination could be assisted with heat, vacuum, or through the use of an adhesive or combination thereof.
  • isocyanates based on HDI are preferred to provide a glass transition temperature below 10° C.
  • Monomeric HDI can be used, but in some embodiments, it is preferred to use oligomers of HDI.
  • Oligomeric HDI can reduce the vapor pressure of the isocyanate to allow safer handling and may provide functionalities greater than 2.0 to provide chemical crosslinking of the energy dissipation layer material.
  • the HDI oligomers can contain functional groups including isocyanurates, biurets, allophanates, uretdiones, iminooxadiazinediones, carbodiimides, or uretoneimines.
  • prepolymers derived from HDI and polyols can be used.
  • polyols may be used to form the cross-linked polyurethane layer.
  • the term polyol includes hydroxyl-functional materials that generally include at least 2 terminal hydroxyl groups.
  • Polyols include diols (materials with 2 terminal hydroxyl groups) and higher polyols such as triols (materials with 3 terminal hydroxyl groups), tetraols (materials with 4 terminal hydroxyl groups), and the like.
  • the reaction mixture contains at least some diol and may also contain higher polyols. Higher polyols are particularly useful for forming crosslinked polyurethane polymers.
  • Diols may be generally described by the structure HO-B—OH, where the B group may be an aliphatic group, an aromatic group, or a group containing a combination of aromatic and aliphatic groups, and may contain a variety of linkages or functional groups, including additional terminal hydroxyl groups.
  • the polyol is an oligomeric polyether such as polyethylene glycol, polypropylene glycol, or polytetramethylene ether glycol.
  • aliphatic polyester polyols are particularly useful.
  • Useful polyester polyols are linear and non-linear polyester polyols including, for example, polyethylene adipate, polypropylene adipate, polybutylene adipate, polyhexamethylene adipate, polyneopentyl adipate, polycyclohexanedimethyl adipate, polydiethylene glycol adipate, polybutylene succinate, polyhexamethylene sebacate, polyhexamethylene dodecanedioate, and poly s-caprolactone and copolymers of these polyesters.
  • the amount of the isocyanate component can be limited. In some embodiments using HDI-derived isocyanates, it can be preferable to use less than 40 wt % isocyanate component based on the total core layer composition, or less than 38 wt %, or less than 35 wt %. In some embodiments, it is preferable to use an isocyanate component containing uretdione groups. When uretdione groups are included, it can be preferable to use an excess of hydroxyl functional groups relative to isocyanate groups.
  • the excess hydroxyl groups can react with the uretdione groups to form allophanate groups to provide cure and chemical crosslinking.
  • the isocyanate index is defined as the molar content of isocyanate functional groups divided by the hydroxyl functional groups.
  • the crosslinked polyurethane is preferably prepared with an isocyanate index between 0.6 and 1.2 or between 0.7 and 1.1 or between 0.75 and 1.05.
  • the degree of crosslinking of the polyurethane energy dissipation layer can be related to the amount of gel content in the urethane.
  • the gel content can be measured by submerging a sample of urethane in a solvent, such as refluxing THF, to extract the non-gel component. The gel content can then be measured gravimetrically by dividing the remaining dried weight after extraction by the weight of sample before extraction.
  • the core layer can have a gel content of greater than 80%, or greater than 90%, or greater than 95%.
  • the reactive mixture used to form the cross-linked polyurethane layer also contains a catalyst.
  • the catalyst facilitates the step-growth reaction between the polyol and the polyisocyanate.
  • Conventional catalysts generally recognized for use in the polymerization of urethanes may be suitable for use with the present disclosure.
  • aluminum-based, bismuth-based, tin-based, vanadium-based, zinc-based, or zirconium-based catalysts may be used.
  • Tin-based catalysts are particularly useful. Tin-based catalysts have been found to significantly reduce the amount of outgassing present in the polyurethane.
  • dibutyltin compounds such as dibutyltin diacetate, dibutyltin dilaurate, dibutyltin diacetylacetonate, dibutyltin dimercaptide, dibutyltin dioctoate, dibutyltin dimaleate, dibutyltin acetonylacetonate, and dibutyltin oxide.
  • dibutyltin dilaurate catalyst DABCO T-12 commercially available from Air Products and Chemicals, Inc., Allentown, Pa. is particularly suitable.
  • the catalyst is generally included at levels of at least 200 ppm or even 300 ppm or greater.
  • the glass transition temperature of the cross-linked polyurethane layer be 10 degrees Celsius or less, or 5 degrees Celsius or less, or 0 degrees Celsius or less, or ⁇ 5 degrees Celsius or less, or ⁇ 10 degrees Celsius or less, or in a range from ⁇ 40 to 5 degrees Celsius, or in a range from ⁇ 30 to 5 degrees Celsius, or in a range from ⁇ 20 to 5 degrees Celsius, or in a range from ⁇ 15 to 5 degrees Celsius.
  • the crosslinked material have a high Tan Delta (>0.5, >0.8, >1.0 or greater than 1.2).
  • This material was represented in the mathematical model as a mixture of 47.5 wt % HDI trimer (168.2 g/equiv.), 25.0 wt % HDI tetramer (210.2 g/equiv.), and 27.5 wt % of HDI pentamer (235.5 g/equiv.).
  • This mixture yields an average equivalent weight of 193 g/equiv. and an average functionality of 3.5.
  • Desmodur N3400 is reported to have an average functionality 2.5 and an equivalent weight of 193, and it is reported to be blend of the HDI isocyanurate trimer and HDI uretdione dimer.
  • This material was represented in the mathematical model as a mixture of 19 wt % HDI isocyanurate trimer, 33 wt % HDI uretdione dimer, and 10 wt % of HDI uretdione trimer and 38 wt % of HDI tetramer having one isocyanurate group and one uretdione group.
  • the functionality was determined by the sum the isocyanate groups and the uretdione groups in the cases where there was an excess of hydroxyl groups relative to the sum of the isocyanate and uretdione groups.
  • a cross-linked polyurethane containing energy dissipation layer or layers may be formed by free radical polymerization of multifunctional urethane acrylate oligomers.
  • the urethane acrylate oligomer may be mixed with other low molecular weight monofunctional and/or multifunctional acrylates to modify the pre-cured viscosity of the resin for the purposes of processing.
  • the average functionality of the multifunctional acrylate used in the energy dissipation layer prior to cure is less than 3 (i.e. 3 functional acrylate functional groups per molecule) or can be 2 or less.
  • the cured (or crosslinked) material may exhibit stable material properties with respect to the display film use in application, that is, the energy dissipation layer may not exhibit appreciable flow.
  • the transparent polyurethane acrylate material may be coated onto the transparent polymeric or glass substrate layer (that may be primed) and then be cured or cross-linked to form a thermoset or cross-linked polyurethane acrylate layer.
  • the polyurethane acrylates described herein are thermosetting polymers that may not melt when heated.
  • Urethane acrylate oligomers can be comprised of a wide variety of urethane materials with acrylate or methacrylate reactive groups. Urethane acrylate oligomers are commercially available from vendors such as, for example, Sartomer of Exton, Pa. (a subsidiary of Arkema) and Allnex (Ebecryl Brand name).
  • Abrasion is a method of wearing down or rubbing away material by means of friction.
  • the abrasion resistance of a material helps it to withstand mechanical action and tends to protect the removal of materials from its surface. This allows the material to retain its integrity and hold its form.
  • Abrasion resistance can be measured by rubbing or wiping the transparent protective layer for a specified number of cycles with a rough material such as steel wool or a scouring pad and then inspecting the layer for visible changes such as fine scratches or haze.
  • the substrate layer (that forms a portion of the protective layer) may have a thickness in a range from 10 to 125 micrometers, or from 25 to 100 micrometers, or from 30 to 85 micrometers.
  • the substrate layer may have a yield stress value greater than 70 MPa, or greater than 90 MPa, or greater than 120 MPa, or greater than 160 MPa.
  • yield stress or “offset yield stress” refers herein to “0.2% offset yield strength” as defined in ASTM D638-14.
  • ASTM D638-14 section A2.6 defines the test method for “offset yield strength” and is defined as the stress at which the strain exceeds by a specified amount (the offset) an extension of the initial proportional portion of the stress-strain curve. It is expressed in force per unit area, usually megapascals (pounds force per square inch).
  • the substrate layer may be formed of any useful polymeric material that provides the desired mechanical properties (such as dimensional stability) and optical properties (such as light transmission and clarity) to the display film.
  • materials suitable for use in the polymeric substrate layer include polymethylmethacrylate, polycarbonate, polyamides, polyimide, polyesters (PET, PEN), polycyclic olefin polymers, and thermoplastic polyurethanes.
  • One useful polymeric material for forming the transparent polymeric substrate layer is polyimide.
  • the polyimide substrate layer is colorless. Colorless polyimide can be formed via chemistry or via nanoparticle incorporation. Some exemplary colorless polyimides formed via chemistry are described in WO 2014/092422.
  • tri(meth)acryl containing monomers such as glycerol triacrylate, trimethylolpropane triacrylate, ethoxylated triacrylates (e.g., ethoxylated trimethylolpropane triacrylate), propoxylated triacrylates (e.g., propoxylated glyceryl triacrylate, propoxylated trimethylolpropane triacrylate), trimethylolpropane triacrylate, tris(2-hydroxyethyl)isocyanurate triacrylate;
  • monomers such as glycerol triacrylate, trimethylolpropane triacrylate, ethoxylated triacrylates (e.g., ethoxylated trimethylolpropane triacrylate), propoxylated triacrylates (e.g., propoxylated glyceryl triacrylate, propoxylated trimethylolpropane triacrylate), trimethylolpropane triacrylate, tris(2-hydroxyethyl
  • Such (meth)acrylate monomers are widely available from vendors such as, for example, Sartomer Company of Exton, Pa.; Cytec Industries of Woodland Park, N; and Aldrich Chemical Company of Milwaukee, Wis.
  • the size of inorganic oxide particles is chosen to avoid significant visible light scattering.
  • the hardcoat composition may comprise up to about 10 wt-% solids of smaller nanoparticles.
  • Such inorganic oxide nanoparticles typically having an average (e.g. unassociated) primary particle size or associated particle size of at least 1 nm or 5 nm and no greater than 50, 40, or 30 nm.
  • the hardcoat may comprise various high refractive index inorganic nanoparticles.
  • Such nanoparticles have a refractive index of at least 1.60, 1.65, 1.70, 1.75, 1.80, 1.85, 1.90, 1.95, 2.00 or higher.
  • High refractive index inorganic nanoparticles include for example zirconia (“ZrO 2 ”), titania (“TiO 2 ”), antimony oxides, alumina, tin oxides, alone or in combination. Mixed metal oxide may also be employed.
  • a tin oxide nanoparticle dispersion (RI 2.0) is commercially available from Nissan Chemicals Corp. under the trade designation “CX-S401M”. Zirconia nanoparticles can also be prepared such as described in U.S. Pat. Nos. 7,241,437 and 6,376,590.
  • the protective layer may be an elastic nanocomposite layer.
  • the elastic nanocomposite layer may be a nanoparticle nanocomposite ionic elastomeric layer, or an elastic nanocomposite urethane layer.
  • the nanoparticle nanocomposite ionic elastomeric layer, or the elastic nanocomposite urethane layer may be directly coated onto the glass layer or optically clear adhesive layer.
  • the nanoparticle nanocomposite ionic elastomeric layer, or the elastic nanocomposite urethane layer may be coated onto a transparent substrate layer, as described above, and the transparent substrate layer is directly attached to the glass layer or optically clear adhesive layer.
  • the elastic limit is the minimum stress at which permanent deformation can be measured.
  • the elastic nano-composite layer may have a strain at the elastic limit that is 20% greater than the strain at the proportional limit, 50% greater than the strain at the proportional limit, or 100% greater than the strain at the proportional limit.
  • FIG. 7 illustrates this concept.
  • the intermediate adhesive layer may have a thickness in a range from 1 to 100 micrometers, or from 5 to 50 micrometers, or 10 to 50 micrometers.
  • An optically clear adhesive layer 13 may fix the glass layer 12 to the protective layer 15 .
  • the optically clear adhesive layer may allow the hardcoat layer to be cleanly removable from the glass layer.
  • the optically clear adhesive layer may have a thickness in a range from 1 to 50 micrometers, or from 3 to 25 micrometers, or from 3 to 15 micrometers.
  • the optically clear adhesive layer may be formed of acrylate, silicone, silicone polyoxamide, silicone polyurea, polyolefin, polyester, polyurethane or polyisobutylene.
  • a coupling layer 24 adheres the display film 10 to the optical element 26 .
  • the coupling layer 24 may be a pressure sensitive adhesive. In some cases the coupling layer 24 permanently fixes the display film 10 to the optical element 26 . In other cases the display film and coupling layer 24 can be removed/debonded/repositioned, relative to the optical element 26 , with the application of heat or mechanical force such that the display film is replaceable or repositionable by the consumer.
  • the coupling layer 24 may have a shear modulus (G′) of 300 kPa or less, or 200 kPa or less, or 100 kPa or less or 50 kPa or less over a temperature range for example ⁇ 40° C. to 70° C., or from ⁇ 40° C. to 50° C., or from ⁇ 30° C. to 50° C., or from ⁇ 20° C. to 50° C.
  • the rheological properties of the material can be measured using a parallel plate rheometer to probe the shear modulus as a function of temperature as well as to determine the glass transition temperature (Tg) of the material.
  • a release liner or premask layer may be disposed on the coupling layer 24 .
  • the release liner may be easily removed for application to an optical display or to reveal the display film, before placement onto an optical display 26 .
  • the removable or release liner (or premask layer) may provide transport protection to the underlying display film and optional coupling layer 24 .
  • the removable liner may be layer or film that has a low surface energy to allow clean removal of the liner from the display film 10 and optional coupling layer 24 .
  • the removable liner may be a layer of polyester coated with a silicone, for example.
  • FIG. 6 is a schematic diagram perspective view of an illustrative folding article 60 including an illustrative display film 10 .
  • the display film 10 may be any of the display film constructions described herein disposed on an optical element such as an optical display 34 .
  • the display device may not be a folding article and may only flex within a certain range, or may be a static curved display device.
  • the display film 10 and the optical display 34 may be foldable so that the optical display 34 faces itself and at least a portion of display film 10 contacts or directly faces another portion of the protective film 10 , as illustrated in FIG. 6 .
  • the display film 10 and the optical display 34 may be flexible or bendable or foldable so that a portion of the display film 10 and the optical display 34 can articulate relative to another portion of the display film 10 and the optical display 34 .
  • the display film 10 and the optical display 34 may be flexible or bendable or foldable so that a portion of the display film 10 and the optical display 34 can articulate at least 90 degrees or at least 170 degrees relative to another portion of the display film 10 and the optical display 34 .
  • the display films described herein may have a haze value of 2% or less, or 1.5% or less, or 1% or less, or 0.5% or less. In some embodiments the display film may have a haze value of 5% or less.
  • the display film may have a clarity of 98% or greater, or 99% or greater.
  • the display film may have a visible light transmission of 85% or greater, or 90% or greater, or 93% or greater.
  • DABCO T-12 Dibutyltin dilaurate catalyst, commercially available from Air Products and Chemicals, Inc., Allentown, PA, under the trade name “DABCO T-12”.
  • CN9004 Aliphatic polyurethane acrylate oligomer, commercially available from Sartomer Arkema Group, Exton, PA.
  • CN3211 Aliphatic polyester polyurethane acrylate oligomer, commercially available from Sartomer Arkema Group, Exton, PA.
  • CD9043 Alkoxylated neopentyl glycol diacrylate, commercially available from Sartomer Arkema Group, Exton, PA.
  • Samples of shape memory polyurethane were prepared in a roll to roll process where the isocyanate and polyol with catalyst were mixed using an inline dynamic mixer. The solutions were applied to a moving web between two silicone release liners at an appropriate flow rate to achieve the desired final sample thickness. The polyurethane between films were heated at 70° C. and wound into a roll. The films were postbaked at 70° C. for 24 hours prior to lamination to glass. Samples had a range of equivalents of NCO reacted with 1.0 equivalents of —OH, as shown in Table 2 in order to achieve the desired glass transition temperature and crosslink concentration. Relative proportions by mass of K-FLEX 188 and Desmodur N3300 for samples 1-5 are shown in Table 2. The coated materials contained about 350 ppm dibutyltin dilaurate catalyst.
  • the NCO + UD/OH ratio accounts for the ratio after the uretdione is reacted with excess OH of the polyol.
  • the N3400 isocyanate contains a uretdione unit that can react with excess OH in the polyol component at elevated temperature to form an allophanate group.
  • the table contains two stoichiometric ratio columns. The first calculates the NCO/OH ratio based on only existing NCO content in N3300 and N3400 at the beginning of the reaction. The NCO+UD/OH ratio accounts for the ratio after the uretdione is reacted with excess OH of the polyol.
  • a Flacktek Inc. size 20 speedmixer cup was added 79.60 g of CN3211 (Sartomer, Inc.) and 19.90 g of SR501 (Sartomer, Inc.). The contents were mixed using a Flacktek DAC 150 FVZ-K speedmixer and were mixed at 3100 rpm for 1 min. The resulting solution was homogeneous near colorless viscous solution. To the speedmixer cup was added 0.5 g of Irgacure TPO-L catalyst. The contents were again mixed at 31000 rpm for 1 min. The resulting solution was then placed into a vacuum oven at 40 Celsius and was degassed to remove all dissolved air and bubbles from the viscous solution.
  • a Flacktek Inc. size 20 speedmixer cup was added 79.60 g of CN3211 and 19.90 g of CD9043. The contents were mixed using a Flacktek DAC 150 FVZ-K speedmixer and were mixed at 3100 rpm for 1 min. The resulting solution was homogeneous near colorless viscous solution. To the speedmixer cup was added 0.5 g of TPO-L catalyst. The contents were again mixed at 31000 rpm for 1 min. The resulting solution was then placed into a vacuum oven at 40 Celsius and was degassed to remove all dissolved air and bubbles from the viscous solution. The solution had a viscosity of ⁇ 5800 cP at room temperature.
  • a Flacktek Inc. size 20 speedmixer cup was added 89.55 g of CN3211 (Sartomer, Inc.) and 9.95 g of SR531 (Sartomer, Inc.). The contents were mixed using a Flacktek DAC 150 FVZ-K speedmixer and were mixed at 3100 rpm for 1 min. The resulting solution was homogeneous near colorless viscous solution. To the speedmixer cup was added 0.5 g of Irgacure TPO-L catalyst. The contents were again mixed at 31000 rpm for 1 min. The resulting solution was then placed into a vacuum oven at 40 Celsius and was degassed to remove all dissolved air and bubbles from the viscous solution.
  • the solution had a viscosity of ⁇ 6000 cP at room temperature.
  • Film samples were made from this resin by coating the resin between a 2 mil thick ZF-50 and a 2 mil thick T50 silicone release coated polyester liner. The solution between films was drawn under a notch bar such a 175 um film was cast. The coating between liners was irradiated under low power 350 nm black light bulbs for 15 minutes to give a cured film with elastic properties.
  • a 3 inch by 6 inch sample of glass was cut using a diamond scribe from a roll of NEG glass (material OA-10G, 300 mm wide, 30 m length, 100 micron thickness).
  • a film sample of shape memory polyurethane was prepared by coating between two silicone release liners. The polyurethane film was made by mixing a polyol containing ⁇ 500 ppm of a tin catalyst and an isocyanate.
  • the Polyol with catalyst (K-FLEX 188) and isocyanate (DESMODUR N3300) were added to separate pump carts with mass flow controllers.
  • the Polyol with catalyst was heated to 60 degrees C. to lower the viscosity.
  • the two components were delivered in controlled stoichiometry from the pump carts via mass flow control to a Kenics static mixer (355 mm long, with 32 elements).
  • the mass flow rate for the Polyol with catalyst and DESMODUR N3300 were to 32.8 g/min and 20.74 g/min respectively to give an overall target NCO/OH ratio for the polyurethane reactive mixture of 0.8.
  • the 2-part polyurethane reactive mixture was coated between two silicone release liners (for example for example T50 release liner available from Eastman Chemical).
  • the reactive mixture was coated to a desired thickness between the release films in a continuous fashion using a notch bar coating method where thickness was controlled by setting a defined gap.
  • the coated polyurethane film was heated at elevated temperature on hot platens to gel the polyurethane film and resulting film was placed into a 70° C. oven for 16 hours to cure.
  • the resulting film with liners was ⁇ 260 um.
  • the polyurethane film was ⁇ 156 um.
  • the glass/polyurethane construction was made by peeling the liner from one side of the polyurethane film and laminating it to the glass. This laminated structure was heated at 70° C. for approximately 24 hours. The second liner was removed and the glass/polyurethane construction was subjected to ball drop and impact testing and results are described in Table 7.
  • a 3 inch by 6 inch sample of glass was cut using a diamond scribe from a roll of NEG glass (material OA-10G, 300 mm wide, 30 m length, 100 micron thickness).
  • a film sample of shape memory polyurethane was prepared by coating between two silicone release liners.
  • the polyurethane film was made by mixing a polyol containing ⁇ 500 ppm of a tin catalyst and an isocyanate.
  • the Polyol with catalyst (K-FLEX 188) and isocyanate mixture (DESMODUR N3300 and Desmodur 3400) were added to separate pump carts with mass flow controllers.
  • the Polyol with catalyst was heated to 60 degrees C. to lower the viscosity.
  • the coated polyurethane film was heated at elevated temperature ( ⁇ 160° F.) on hot platens to gel the polyurethane film and resulting film was placed into a 70° C. oven for 16 hours to cure.
  • the resulting film with liners was ⁇ 240 um.
  • the polyurethane film was ⁇ 136 um.
  • the viscous mixture was applied to the surface of the glass by placing the glass sample between two silicone release liners and coating the polyurethane over the glass sample by pulling two release liners with polyurethane under a notch bar having a defined gap to produce a 100 um thick coating of polyurethane on 100 um thick glass.
  • the sample between liners was cured at 70° C. for 24 hours.
  • the two release liners were removed to give the glass and polyurethane construction.
  • the construction was subjected to ball drop and impact testing and results are described in Table 7.
  • a 4 mil layer of an optically clear adhesive (3M 8146 OCA) was laminated to a 100 micron thick NEG glass layer as described in Example A.
  • a 2 mil PET film (Available from DuPont) was laminated to the other side of the adhesive.
  • the glass/OCA construction with 2 mils of OCA between the glass and PET layers was subjected to ball drop and impact testing and results are described in Table 7.
  • fixed of “coupled” or “connected” refer to elements being attached to each other either directly (in direct contact with each other) or indirectly (having one or more elements between and attaching the two elements).
  • phrases “at least one of,” “comprises at least one of,” and “one or more of” followed by a list refers to any one of the items in the list and any combination of two or more items in the list.

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